Modular frame and enclosure system

ABSTRACT

The invention is a modular frame system that can be used to construct free-standing enclosures for equipment. The modular system includes interchangeable frame members connected to transition members that can together be arranged to form an orthogonal frame. Other accessory components can be attached to build an enclosure system. The invention envisions utilizing composite materials in constructing enclosures, with such embodiments having an enhanced strength to weight ratio. The frame system is constructed of frame members that facilitate alignment and attachment of other system accessory components through use of regularly spaced upstanding male connectors that engage with regularly spaced depressed female connectors. Thus, there is great flexibility in attachment of components and adapting the enclosure system to particular applications. Frame members of the invention can alternatively be used as construction components in a variety of building systems.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to provisional application Ser. No.60/581,999 filed Jun. 22, 2004.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not applicable.

BACKGROUND OF THE INVENTION

Enclosures are used for a number of applications, including threegeneral categories: to provide environmental protection of equipment; toprovide a rack or mounting space in which to mount equipment such ascomputer equipment; and to enclose controls for the utility and energyindustries. The enclosure industry is very broad in terms of specificenclosure applications and configuration of the enclosure to houseparticular products. Broad categories of product configurations includelarge freestanding units, wall mount units, junction boxes, instrumenthousings, consoles, operator interfaces and kiosks.

The market in the United States alone for industrial enclosureapplications is estimated to exceed $1 billion annually, withapproximately half of the dollar value consisting of free-standingenclosures. The general form of most enclosures is orthogonal, eithersquare or rectangular in cross section, although for certainapplications other cross sectional shapes may be useful, includingtrapezoidal, hexagonal and octagonal.

Other variations on the basic form of an enclosure embodied by thefreestanding enclosure include wall mounted boxes, operator interfacecubicles, along with accessory products such as swing frame mountingpanels, doors, partitions and wire way. Many enclosure systems aredesigned to conform to the Electronic Industry Association 310c standardfor hole spacing and location to allow for mounting standard 19 inchequipment on rails (EIA rail).

One difficulty for manufacturers is shipping enclosures is that anassembled enclosure has a very high space to weight ratio. Thereforeshipping and handling of assembled enclosures is problematic, asshipping assembled enclosures requires substantial volume. Asmanufacturers attempt to ship more compact, disassembled components toorder minimize shipping costs, there is an efficiency trade-off for theend user, who must either pay to have a technician assemble theenclosure, or assemble the enclosure on site, where time, toolavailability, and mechanical skill may limit the ability of the end userto configure an enclosure product in an optimal manner.

As many end users who have attempted to assemble an unfamiliar enclosureor other furniture can attest, basic unfamiliarity of the method ofassembly of a complex product of many unfamiliar parts can be afrustrating and often laborious process.

For these reasons modular enclosure construction styles have provenpopular because of ease of assembly and ready access, flexibleconfigurations, and capability of expansion. Performance of enclosuresutilizing modular construction is limited relative to “unibody”free-standing enclosures with regards to structural rigidity, weightcapacity, and other logistical requirements. Some of these limitationsof modular construction technology can be eliminated by addingstructural reinforcements, usually through adding selected accessoryproducts at additional costs in weight, labor and acquisition price.

A variety of materials have been used to construct enclosures.Freestanding enclosures have utilized mild carbon steel, stainlesssteel, aluminum and fiberglass reinforced polyester. Considerations ondetermining the material used in an enclosure include the weight of theenclosure, with heavier materials limiting portability; the weightbearing capacity of the enclosures, with steel being typically used forenclosures carrying heavier loads; and corrosion protection, withenclosures being used in corrosive environments being constructed ofstainless steel or polyester.

A number of other performance versus cost balancing factors may beconsidered when determining the material used and the constructionmethod depending on the particular enclosure application These factorsinclude ease of assembly, need for electromagnetic interference (EMI)shielding, shock and vibration resistance, requirement for explosionprotection, enclosure accessory requirements, thermal management,vandalism resistance, hygiene, environmental protection ratings,electrical properties, and industry standards and municipal codes.

Recently, hybrid materials have been developed that combine metalsupport members with integrated plastic reinforcements. See U.S. Pat.No. 5,190,803 and 6,421,979, the disclosures which are incorporatedherein by reference.

There is a need in the enclosure industry for enclosures exhibiting highstrength to weight ratio, user configurable structure, capacity forenvironmental protection and environmental control and relative ease ofassembly. The invention disclosed herein offers advantages in many areasimportant for the design and performance of an enclosure system. Whenembodied through the use of composite construction, includingmetal/plastic hybrid material, there are advantages in strength toweight ratio and enabling the optimization of material properties for aparticular application. Additionally the modularity of construction,ease of alignment, and utilization of materials with a high strength toweight ratio have applications in many areas of the furniture,construction and other industries.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to a method for producing modularframes that have wide application in the furniture, enclosure,construction and other industries. One embodiment provides a rigid racksystem that can serve as the frame for freestanding enclosures and ifused in conjunction with other modular components of the invention, canbe used to construct secure freestanding enclosures for electronic andother equipment.

The invention is embodied in a method of making a frame comprising thesteps of providing two or more linear frame members exhibiting framecontact peripheries at the ends and a frame cross-section presenting atleast one contact edge along the axis of the frame edges. An additionalembodiment of the invention are one or more transition members that forma junction and or corner connection between linear frame components.Ideally, the transition member will exhibit a contact periphery in atleast two contact planes. The invention is embodied in aligning a framecontact periphery of a frame member with a first edge profile andabutting a linear frame member to a first contact surface of atransition member, aligning a frame contact periphery with a second edgeprofile and abutting a linear frame member to a second contact surfaceof a transition member and then aligning a frame contact periphery witha third edge profile and then abutting a linear frame member to a thirdcontact surface of a transition member. By reiterating the aligning andcoupling steps, a three dimensional frame can be constructed accordingto the invention, utilizing transition members with four or more contactsurfaces.

The invention is embodied in a means for connecting and aligningtransition members and frame members by providing one or more studconnectors each having first and second connector portions in a more orless linear orientation. Linear frame members are provided with two ormore with frame connector cavities extending axially and mutuallyinwardly from the frame contact ends. Another embodiment of theinvention is the connection of frame members to transition members eachbeing configured with a transition connector cavity extending axiallyinwardly from first, second, third and or fourth contact surfaces. Thusthe steps of aligning and coupling a transition member with framemembers can be carried out by inserting a stud connector first connectorportion within a frame connector cavity and inserting said studconnector second connector portion within a said transition connectorcavity. Alignment and permanent connection are embodied in the use ofconnector clips and locking spacer collars.

The invention is also embodied in a transition member or frame memberbeing configured having an outwardly disposed flat surface having one ormore frame carrying connectors, or nubs, integrally formed with the flatsurface. Frame members can be configured with regularly spaced carryingconnectors, with the carrying connectors lending modularity to the framemembers of the invention. The steps of aligning and coupling a framemember locates the frame member and or a transition member with theoutwardly facing flat surface that is aligned, thus providing forattachment of a corner completing accessory of the invention, in oneembodiment having a cross-section of triangular shape to define a cornerby interconnecting frame carrying connectors with accessory connectors.The invention is also embodied in a system and method in which one ormore frame members with one or more flat surfaces having an array ofsaid frame carrying connectors which are outwardly depending maleconnectors and providing an accessory component with accessory carryingconnectors as inwardly depending female connectors. The invention isfurthermore embodied in a system and method in which one or more framemembers with one or more flat surfaces having an array of said framecarrying connectors which are inwardly depending female connectors andproviding an accessory component with accessory carrying connectors asoutwardly depending male connectors.

According to the invention is a method for aligning and coupling two ormore frame members or other frame components with one or more transitionmembers carried out to derive a frame structure with two or moreadjacent bays where two vertically oriented frame members are locatedwith a linear edge of one frame member abutting a linear edge of theadjacent frame member. Thus, the cross section of each frame is, in apreferred embodiment, generally square to provide two angularly orientedframe faces extending outwardly from the abutting linear edges. Theadjoining frames can be sealed by installation of a resilient gasket andby further providing an inter-bay completing accessory having across-section of triangular shape and having accessory connectorscorresponding with an array of frame carrying connecters, thus couplingthe inter-bay completing accessory at the respective side faces to theangularly oriented frame faces by interconnecting frame carryingconnectors with accessory connectors.

Another embodiment of the invention is a frame constructed according tothe invention that possesses continuous transition edges, capable offorming a tight seal, especially when employed with a gasket ofresilient material. Furthermore, frame systems of the invention can bestacked vertically, and connected in a manner analogous to thehorizontal connection just described.

The invention is further embodied in frame members whose framecross-section defines four flat orthogonally disposed surfaces with oneor more said flat surfaces having a said frame connecter assemblagecomprising an array of frame connectors, with each transition memberback surface frame carrying connector assemblage comprises an array ofsaid frame connectors. The frame connectors are embodied as outwardlydepending male connectors and the accessory connectors are embodied asinwardly depending female connectors. Additionally, the frame connectorsare embodied as inwardly depending female connectors and the accessoryconnectors are embodied as outwardly depending male connectors. In apreferred embodiment of the invention the frame cross-section isrectangular or substantially square, although other cross-sectionalshapes can be used to practice the invention.

The invention is embodied in a frame system, comprising a plurality oflinear frame members of given lengths extending along a frame axisbetween oppositely disposed contact ends, with the contact endsexhibiting frame contact peripheries. The frame system may include aplurality of transition members. The frame possesses a plurality oftransition members being designated lower frame transition members, anda plurality being designated upper frame transition members, a pluralityof the frame members being designated vertical frame members, and aplurality being designated horizontal frame members. The oppositelydisposed contact ends of a plurality of the vertical frame members beingcoupled between the first contact surface of a plurality of the lowerframe transition members and the fourth contact surface of a pluralityof the upper frame transition members. The oppositely disposed contactends of a plurality of the horizontal frame members being coupledbetween the second contact surfaces and the third contact surfaces of aplurality of lower frame transition members to define a lower frameportion; and the oppositely disposed contact ends of a plurality of thehorizontal frame members being coupled between the second contactsurfaces and the third contact surfaces of a plurality of upper frametransition members to define the upper frame portion of a frame having aplurality of vertically disposed corner regions extending betweenoppositely disposed upper frame transition members and lower frametransition members.

Yet another embodiment of the invention are frame members configuredhaving an open channel extending between frame component ends. Framemembers can be designed to function independently as modularconstruction elements, including as conduits, or with a designspecialized for construction of a modular frame system. Frame membersand transition members can be configured according to the inventionhaving joined open channels with the transition member cavities beinggenerally aligned with a frame cavity when their respective contactperipheries are aligned. The frame system is also embodied in one ormore of said frame members comprising a generally U-shaped channelcomponent having an outwardly open cap receiving side and configuredwith a generally U-shaped reinforcing member having three outwardlydisposed frame faces and a reinforcing member cavity extending betweenthe oppositely disposed contact ends. Preferably, a polymeric channelmatrix member is located within the reinforcing member cavity configuredto define a portion of the frame connector cavities extending inwardlyfrom the frame contact ends and further configured to define a matrixbottom wall and side walls extending outwardly to spaced apart capengagement ledges adjacent to the outwardly open cap receiving side. Acap component is provided, configured for positioning over theaforementioned channel component open cap receiving side and having agenerally flat cap reinforcing member with an outwardly disposed frameface and an inwardly attached polymeric cap matrix member havingoppositely and axially disposed spaced apart engagement surfacesengaging said spaced apart cap engagement ledges, the cap matrix member,with the channel matrix member, defining the frame connector cavities. Aconnector assembly coupling said cap component with said channelcomponent, including manifold blocks to direct airflow and provideaccess to the frame member cavity are provided. Although a frame memberwith a square cross-section in mentioned as a preferred embodiment,other cross-section of frame members can be used to practice theinvention.

Other objects of the invention will, in part, be obvious and will, inpart, appear hereinafter. The invention, accordingly, comprises theapparatus and method possessing the construction, combination ofelements, arrangement of parts and steps which are exemplified in thefollowing detailed description.

For a fuller understanding of the nature and objects of the invention,reference should be had to the following detailed description taken inconnection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an assembled enclosure incorporatingthree frames according to the invention with accessory panels andequipment installed on the frame;

FIG. 2 is a perspective view of an assembled enclosure frame;

FIG. 3 is a perspective view of frame members joined by a transitionmember;

FIG. 4 is a perspective view of a transition member in association withstud connectors;

FIG. 5 is a an exploded view of a transition member and in associationwith stud connectors;

FIG. 6 is a top view of a transition member is revealed in connectionwith stud connectors;

FIG. 7 is a sectional view along line 7-7 of FIG. 6 showing a transitionmember in connection with stud connectors;

FIG. 8 is a perspective exploded view of a frame member and relatedcomponents;

FIG. 9 is a partial sectional view of an assembled frame, such sectionbeing taken across the transition edges of both the transition membersand the linear frame members;

FIG. 10 is a perspective view of a manifold screw;

FIG. 11 is a sectional view of the cap component described in connectionwith FIG. 8;

FIG. 12 is a sectional view of a cap component according to theinvention showing an alternate embodiment;

FIG. 13 is a sectional view of a cap component according to theinvention showing an alternate embodiment;

FIG. 14 is a sectional view of a cap component according to theinvention showing an alternate embodiment;

FIG. 15 is a top view of an assembled enclosure;

FIG. 16 is a perspective view of an accessory component of triangularconfiguration;

FIG. 17 is a sectional view of a triangular accessory componentinstalled on a frame member;

FIG. 18 is a sectional view of a triangular accessory componentinstalled on a frame member; and retained by screws;

FIG. 19 is a perspective view of an alternative embodiment of anaccessory component of triangular configuration with both simple andcammed female connectors;

FIG. 20 is a sectional view of an alternative embodiment of an accessorycomponent of triangular configuration locked on a frame member with acammed female connector;

FIG. 21 is a bottom view of the locking arrangement of an accessoryblock with a cammed female connector;

FIG. 22 is a sectional view of a horizontal accessory bar installedbetween two frame members;

FIG. 23 is an end view of a accessory component with elongated femalecarrying connectors.

FIG. 24 is a top view of an accessory component exhibiting thecapability of modular interconnection;

FIG. 25 is a side view of an accessory component such as that shown inFIG. 24.

FIG. 26 is a top view of a modular accessory component that can connectframe members and that has a locking cam connector;

FIG. 27 is a side view of an accessory component such as that shown inFIG. 26.

DETAILED DESCRIPTION OF THE INVENTION

The invention is embodied in a modular frame system that can be used toconstruct free standing enclosures for equipment. In the discourse tofollow an enclosure is generally described which incorporates the framesystem and method of the invention. Then, the uniquely developed framesystem is described including the utilization of linear framed membersand transition members which function to define corners as well as toevolve continuous transition edge which falls within a common transitionplane permitting an ideal sealing of the cavity defined by theenclosure. The discussion then turns to the structuring of the frame andtransition members as they are combined to form an enclosure. To achievea continuous edge within each transition plane the frame members arerotated in effect an amount of about 45°. However, to reconstitute thesides or skin of an enclosure, accessories are provided which, ineffect, return frame surfaces to a conventional orientation. The framesystem is constructed of frame members that facilitate alignment andattachment of other system components, such as sealing panels, hingeddoors, shelves, drawer tracks, or decorative panels.

The modularity of the components of the invention is illustrated by theinterchangeability of horizontal and vertical frame members. While it ispossible to construct horizontal and vertical frame members of theinvention with different cross sections, for instance with rectangularand round cross sections respectively, modularity and interchangeabilityof system components is enhanced by producing horizontal and verticalframe members with the same cross section, for instance a square crosssection.

In a preferred embodiment, all frame members or frame member componentsare hollow. When a frame is assembled from hollow frame members, studs,and manifold blocks, there will exist a frame cavity that forms acontinuous passageway throughout the structure of the assembled frame.This hollow construction facilitates the application of a number ofaccessory elements to adapt the assembled frame for a particularapplication.

Frame members can be cast, molded or extruded from a wide range ofmaterials including thermoplastics and thermoset compounds such aspolyamides, polyethylene, polysulfones, polycarbonates, polystyrene,polyester or vinyl resins, epoxy resins, and phenolic resins includingcopolymers and blends and these materials in reinforced or filled formor from other materials known to those skilled in the art, depending onthe requirements of a particular application. Materials to fill,reinforce or modify the above materials include fibers or woven fabricsof glass carbon or textiles and modified natural substances such as woodparticles and mineral fibers. Frame members or particular componentscould be milled or formed, including from metals such as steel,stainless steel, aluminum, and titanium and alloys of these or otherappropriate metals.

Referring to FIG. 1, an enclosure incorporating three frames isrepresented in general at 10. Enclosure 10 incorporates three baysrepresented generally at 12, 14 and 16 formed with a corresponding threeinternal frames that are interconnected. Some components of the internalframe are seen within the bay 12 that is associated with a door 18fastened to the frame at hinges 20-22. Portions of the frame revealed inbay 12 are seen to include a vertical frame member 24 as well ashorizontal frame members 26 and 28. These frame members generallyexhibit a rectangular cross-section which preferably is square. Withsuch an arrangement, two generally horizontally disposed opposite edgeswhen combined with transition members define a continuous transitionedge which resides within a transition plane. This permits an idealsealing such that a seal as shown at 30 mounted upon the inside of door18 will engage that transition edge in an ideal manner. Portions of thetransition edge are seen at 32. Enclosure 10 rests upon a plinth 34 andis configured with lifting eyes certain of which are identified at 36.

Looking to FIG. 2, an illustrative frame is represented in general at38. Frame 38 is formed with four principal vertical frame members 40-43,and at a lower frame portion represented generally at 44, fourhorizontally disposed frame members 46-49 are illustrated.Correspondingly, the frame upper portion represented generally at 50 isseen to incorporate four horizontal frame members 60-63. The figureillustrates the unique orientation of the frame members in that theyare, in effect, rotated by an amount of 45° from what may be considereda conventional structuring for an enclosure frame. To interconnect theseframe members and accomplishing the earlier-noted continuous transitionedges, horizontal and vertical components are interconnected byidentically structured transition members shown in the figures at 64-71.These transition members are uniquely structured to establish theearlier-described co-planar transition edge profile. In this regard, twooutwardly disposed profiles are seen in the figures at 72 and 74.Correspondingly, an inwardly disposed transition profile which iscontinuous is seen at 76-78. Such profiles are present at each side ofthe frame 38. With such an arrangement, components of the enclosure maybe, in effect, sealed for pressurization and the like. As anotherfeature, the transition members as at 64-71 as well as the frame membersare structured, as noted above, to carry cooling fluids or be utilizedas a race for carrying wiring and the like. Lower region transitionmembers 46-49 also are seen coupled with respective feet 80-83. Thesefeet may be structured in the same manner as the frame members or may beformed as simple blocks or the like. Note, additionally, that thetransition members are configured having a flat back surface, forexample, as represented as at 84 in connection with transition member71, and 86 in connection with transition member 67. Finally, it may beobserved that the surfaces of frame members carry frame carryingconnectors 88, and the back surfaces, for example, at 84 and 86 of thetransition members also carry frame carrying connectors 88.

Referring to FIG. 3, vertical frame member 42, foot 82 and horizontalframe members 48 and 49 are illustrated in perspective fashion inconnection with transition member 70. Linear frame member 49 is seenextending to a contact end represented generally at 90; vertical framemember 76 is seen extending to a contact end 92 and foot 82 is seenextending to a contact end 94. Each of those contact ends exhibits aframe contact periphery, here corresponding with a square framecross-section. Such an arrangement provides two symmetrically oppositelinear edges, for example, one such edge is shown at 96 in connectionwith linear frame member 49. Note that linear edge 96 is outwardlydisposed. In similar fashion, an outwardly disposed linear edge is shownat 98 in connection with vertical frame member 42. An outwardly disposedlinear edge is shown at foot implemented frame member 82 as at 100. Aninwardly disposed linear edge which is symmetrically oppositely disposedfrom a corresponding outer linear edge is shown at 110 in connectionwith horizontal frame member 48.

One embodiment of the invention is the relative orientation of thetransition edges of different frame members. One advantage of threadedconnector studs as in 140 along with locking spacer collars as in 166 isthe capability to install frame members in a chosen orientation relativeto one another. In a further embodiment of the invention, other shapesof frame members can also be oriented relative to the transition membersto expose an outwardly facing transition edge, disposed in a plane. Byadjusting the orientation of frame members through use of connectorstuds and locking spacer collars, frame members of triangular,rectangular, pentagonal, hexagonal, or octagonal cross section can beoriented to expose a sealing edge in a plane. Certain cross sections offrame members can also be oriented to expose an inwardly facing sealingedge.

Now looking to the transition members as at 70, each is typically formedwith four cognitively disposed components. The first such component isrepresented generally at 112 and is seen to be disposed about avertically oriented first axis identified at 114. Component 112 providesa first contact surface 116 which exhibits an edge profile whichcorresponds with the earlier-noted frame contact periphery. That edgeprofile is oriented about the first axis 114 to position two oppositeedges within a first plane extending through the axis 114.

Transition member 70 further is configured having a second component 118extending along a second axis 120 to a second contact surface 122.Surface 122 exhibits an edge profile corresponding with thecross-section of frame member 49 and is oriented about the second axis120 to position two opposite edges and a second plane normally disposedwith respect to the noted first plane. One of those edges has beendescribed at 96. The figure permits the illustration of this secondplane as at 124.

Not seen in this figure is a third component extending along a thirdaxis represented at 128. That component is oriented about axis 128 suchthat two opposite edges, one of which has been described at 110 liewithin the earlier-noted second plane 124. Finally, a fourth componentis represented generally at 130 extending along the first axis 114opposite the first component to a fourth contact surface representedgenerally at 132. Surface 132 exhibits an edge profile correspondingwith the cross-section, for example, of foot or frame member 82. Nowlooking to the transition edges of transition member 70, note that anoutermost one of two edges as shown at 134 with respect to the first andsecond components interact with contact surfaces 122 and 116 incontinuous fashion and within a transition plane. Note that this edgeexhibits a medial curvature as represented generally at 136. It may beobserved that the outermost edges 98 of the first frame member 42 andthe corresponding outermost edge 96 of frame member 49 define acontinuous transition edge within a common transition plane. A similargeometry is present with respect to each of the four transition membercomponents. In those situations where less than four frame membercomponents are to be joined, transition members can be constructed withtwo, or three, cognitively disposed components. The figure furtherreveals the presence of connector screws certain of which are identifiedat 138.

In a preferred arrangement, the linear frame members are interconnectedwith the transition members utilizing stud connectors. Looking to FIGS.4 and 5, transition member 70 again is reproduced but in associationwith three stud connectors 140-142. In FIG. 5 portions of the first andsecond contact surfaces 116 and 122 are revealed extending inwardly fromeach such contact surface as internally threaded opening 144 and 146which, in combination with the internal openings of the other transitionmember components define a transition connector cavity providing for theacceptance of cooling fluids or wiring. FIG. 5 reveals that each of thestud connectors 140-142 is configured with a externally threaded firstconnector portion shown respectively at 148-150 and an integrally formedsecond connector portion shown respectively at 152-154 exhibiting asquare cross section in this embodiment of the invention. An openchannel as shown respectively at 156-158 extends through each of therespective stud connectors 140-142. Additionally, a threaded engagementtap is provided within each stud connector, certain of which arerevealed at 160. Additionally, the second connector portion of each ofthe stud connectors is configured with inner and outer connectorchannels, certain of which are identified at 162 and 164, respectively.When these stud connectors are threadably engaged with the transitionmember as at 70 they are secured from rotation by locking spacercollars, certain of which are revealed at 166. Locking spacer collars asat 166 are secured in place by machine screws, certain of which areidentified at 168. The thickness of locking spacer collar 166 can beadjusted by the user to accommodate tolerances needed to align theassembled frame. The threaded openings in the stud connectors asdescribed at 160 are located to receive connection screwsearlier-described in connection with FIG. 3 at 138.

Referring to FIG. 6, a top view of the transition member 70 is revealedin connection with stud connectors 140-142 and their associated lockingspacer collars 166, as shown previously in perspective view in FIG. 4.The figure also reveals that the back surface 84 is arrangedperpendicularly or normally to an axis 170. Axis 170, in turn, bisectsaxes 120 and 128. Also identifiable in FIG. 6 is a transition plane 171as well as a transition plane 172. It may be recalled that thecontinuous transition edge profile falls within such transition planes.

Looking to FIG. 7, a sectional view along line 7-7 shown in FIG. 6 isrevealed. Referring to the sectional view of FIG. 7, theearlier-described transition connector cavity is illustrated and nowrepresented generally at 174. Note that the cavity is formed from fourinternally threaded openings. In this regard, note that openings 144 and146 return from FIG. 5. In addition to these openings, note that thefigure reveals threaded openings 176 and 178.

Now considering the structuring of the linear frame members, referenceis made to the exploded view of FIG. 8. In the figure, an exemplaryframe member is represented generally at 190. A preferred embodiment ofthe invention is utilization of linear frame members in the constructionof a modular frame system. An embodiment of the invention are framemembers formed from hybrid materials combining a matrix member and areinforcing member. Polymeric materials which may be employed with thehybrid frame members as well as for the formation of the transitionmembers. The basic principle of utilizing hybrid materials to formcomposite construction elements is illustrated in U.S. Pat. No.5,190,803. Typically the body matrix member is formed from some type ofpolymeric plastic or composite material through molding or extruding. Ifthe reinforcing member is formed from metal, the shape of thereinforcing member can be produced by pressing, rolling or other means.The components of the hybrid material system can be joined togetherduring the forming process, for instance, by inserting the reinforcingmember into a mold and then injecting plastic utilized as a matrixmember into the mold. One of many alternative means for forming acomponent of hybrid material is to separately form the body matrixmember, and then join the matrix member to the reinforcing member. Suchas process is illustrated by U.S. Pat. No. 6,421,979, with saiddisclosure expressly incorporated herein by reference. Artisans willrecognize that the particular materials utilized are highly diverse, andparticular materials may be chosen for specialized applications. Thus,although polymeric matrix members formed of plastic are a preferredembodiment, and the matrix element is referred to as a polymeric matrix,as is obvious to artisans, the invention is not limited only to matrixelements of a polymeric or plastic nature.

Another embodiment of the invention is as a hollow construction element.When a hollow construction element is formed from composite materials asdescribed the construction element of the invention can be used toconstruct wireway conduit that can be used separately, or in conjunctionwith the frame system and enclosures of the invention. It is apparentthat the construction elements shown in FIG. 8 is readily adaptable as aconduit. If the construction element is made with a removable cap, as inFIG. 8, positioning of material within the conduit would be enabledfurthermore, a conduit constructed using the composite materialsdescribed will have advantages of strength to weight ratio overconventional single material conduit, whether of metal or plasticconstruction.

Frame member 190 shown in FIG. 8 is formed with regularly spaced malecarrying connectors 248 on the outside surfaces. If the frame member isformed of a single material, male connectors can be formed of the samematerial as the frame member. When employing hybrid materials asdescribed, the advantage of the provision for regularly spaced maleconnectors is apparent. When forming a composite construction element ofhybrid materials, means must be provided for affixing the body matrixelement to the reinforcing element. One method that has previously beenused to anchor body matrix material to the reinforcing element is topass body matrix material through perforations in the reinforcingelement so that the body matrix material is formed to integrally connectwith the reinforcing element. See U.S. Pat. No. 5,190,803. The inventionprovides for a method for forming a hybrid or composite constructionelement wherein the body matrix is fixed to the reinforcing elementthrough perforations or indentations that can be used to form regularlyspaced male connectors.

Referring to again to FIG. 8, is seen one embodiment of frame members ofa hybrid construction, combining a reinforcing member 196 with apolymeric matrix member 208, formed using either injection molding orextrusion as shown. In a preferred embodiment, horizontal and verticalframe members are constructed as shown in FIG. 8. Frame 190 is formedwith a generally U-shaped channel component represented generally at192. Component 192 is configured with an outwardly open cap-receivingside represented generally at 194 and is seen to be configured with agenerally U-shaped reinforcing member represented generally at 196.Reinforcing member 196 configured with three outwardly disposed framefaces 198-200 and a reinforcing member cavity represented generally at202 which extends between oppositely disposed contact ends 204 and 206.A polymeric channel matrix member represented generally at 208 islocated within the reinforcing member cavity 202. Matrix component 208is configured to define a portion of the frame connector cavitiesextending inwardly from the frame contact ends 204 and 206. That cavityportion is represented in general at 210. Matrix member 208 is seen tobe configured to define a matrix bottom wall 212 and oppositely disposedside walls 214 and 216 which extend outwardly to spaced apart capengagement ledges shown respectively at 218 and 220.

Note that screw ports, certain of which are identified at 222 extendthrough the sides of the frame member for communication within the frameconnector cavity portion 210. Such screws are represented, for example,at 138 and correspond with screws as described at 138 in FIG. 3. Such aconnecting arrangement is provided for all four sides of the linearframe member. The spaced apart cap engagement ledges 218 and 220 areoperatively associated with a removable cap component representedgenerally at 224. Component 224 is configured generally for positioningover the channel component open cap receiving side as well as theoppositely disposed cap engagement ledges 218 and 220. Note that the capmember incorporates three cap screw ports 225 analogous to earlieridentified screw ports at 222. Screw ports can be formed during themanufacture of frame members and regularly spaced along the walls of theframe members. In the alternative means to produce screw ports can beformed during manufacture of the frame member by providing means forpunch out holes by scoring the reinforcing member and or the matrixmember. Screw ports 222 and 225 are shown as circular in shape, butother embodiments of screw ports 222 and 225 could be oval, rectangular,or an extended rectangle forming a slot. Those screw ports not incurrent use could be closed using a plug shaped to fit a particular holeshape.

Certain stud connectors as represented generally at 226 are coupledwithin the frame connector cavity. In this regard, the first connectorportion 228 of stud connectors as at 226 is mounted within the frameconnector cavity utilizing generally U-shaped retaining clips. In thisregard, two lower disposed such clips are shown at 232 and 234 which arelocated within respective matrix clip channels 239 and 238.Corresponding matrix clip channels are shown at 240 and 241. Thosechannels are aligned with the inner and outer stud connector clipchannels here identified in connection with stud 226 at 236 and 237.Those channels are seen to be in alignment with inner and outer capchannels 240 and 241. Corresponding inner and outer cap clip channelsare shown at 243 and 244. These cap channels receive upper retainingclips 231 while the said channels additionally are retained by lowerretainer clips (not shown) but as described above at 232. Retainingclips are shown as separate parts of two pieces, which would allowretaining clips to be made of a different material than the attachmentstud. In the alternative, connector stud 226 can be formed with anintegral rib shaped to fit the retaining clip channel of frame memberchannel component 192 and frame member cap component 224.

A manifold block also may be located within the frame cavity. One suchmanifold block is represented generally at 250 and is shown configuredwith six mutually communicating threaded openings. Three of thoseopenings are shown at 252-254. Depending on the length of the framemember and any requirements for additional reinforcement ormodifications of an assembled frame member, one or more of manifoldblock 250, when inserted and aligned with one of the screw ports 222 maybe connected in position by machine screws as at 138 to provideintermediate structural support for the linear frame member. Manifoldblock 250 can be made with one or more threaded holes 252, or could besolid.

The frame member shown in FIG. 8 will be hollow when assembled,facilitating the passage of wiring and/or fluids for temperatureregulation. This embodiment of a frame member facilitates insertion ofwiring harnesses in the frame cavity 210. As an additional function, themanifold blocks as at 250 may permit communication from exterior of theframe members through these screw ports as at 222 and 225. In thisregard, for example, wiring harnesses and or cooling fluids may beconveyed through that port arrangement. Before final assembly of aframe, a wiring harness can be inserted into the frame member channelcomponent 192, and threaded through intervening intermediate framemembers, connector studs, and manifold blocks. When the wiring harnessis located according to the requirements for the particular enclosure,the ends of the wiring harness can be threaded through an screw hole ina frame member, and the frame member cap component 224 secured to framemember channel component 192. Those skilled in the enclosure art canenvision other applications for a continuous frame cavity beyondproviding a conduit for wiring.

Returning to the cap 224, a configuration is illustrated which includesa generally flat frame cap reinforcing member 256 which preferably isformed of metal and exhibits an outwardly disposed frame face 258 and aninwardly attached polymeric cap matrix member 260. Matrix member 260 isconfigured having oppositely and axially disposed spaced apartengagement surfaces 262 and 264 configured to engage respective capengagement ledges 218 and 220. The cap 224 is assembled against the capreceiving sides 194 through the utilization of connector screws, certainof which have been identified at 138 which extend through ports as at225 extending through the cap. These screws will engage the threadedopenings in oppositely disposed stud connectors as described earlier at160. Frame member channel component 194 will typically have screw holes222 aligned with the threaded holes 160 of connector stud 226, andscrews 138 can likewise be driven into the connector stud to reinforcethe retention of the connector stud in the frame member. The framemember channel component, connector stud and frame member cap componentcan also be assembled alternatively, or additionally, using an adhesiveor other joining means. Additionally, intermediately disposed screws maybe threadably engaged with one or more interval manifold blocks at 250.When joined, the frame member channel and frame member cap will form aframe member with a rectangular cross section, although the inventioncan be practiced with frame members of a number of different crosssections.

As described above, the linear frame members as at 190 are of a hybridnature combining a polymeric matrix with a metal exterior. The membersfurther are configured with an array of outwardly depending polymericmale connectors or nubs, certain of which are identified at 248. Theseconnectors will be seen to be configured in a variety of shapes andmaterials. The outwardly disposed surfaces of frame members can beembodied to carry nubs or outwardly disposed male frame carryingconnectors 248. As explained in greater detail below, the outwardlydisposed male connectors will in preferred embodiments serve a dualrole, serving both as a means to fix the polymeric matrix component toframe reinforcing members and also as a means of connecting accessorycomponents.

Referring now to FIG. 9, a partial sectional view of an assembled frameof the invention is revealed, such section being taken across thetransition edges of both the transition members and the linear framemembers. In the figure, upper frame portion is represented generally at280, while the lower frame portion is represented in general at 282. Avertical linear frame member is represented generally at 284 extendingbetween the upper and lower portions. Frame member 284 is seen to beconfigured having oppositely disposed transition edges 286 and 288 whichare structurally associated with polymeric matrix components asdescribed in connection with FIG. 8 and shown at 290. Thus, a frameconnector cavity 292 is developed between oppositely disposed contactends 294 and 296. As before, those contact ends exhibit frame contactperipheries which exhibit a frame cross-section having noted twosymmetrically opposite linear edges 286 and 288. These contact ends areconnected in abutting relationship against the contact surfaces 298 and300 of respective transition members 302 and 304. A stud connector 306couples transition member 302 to the top of frame member 284, while anoppositely disposed stud connector 308 connects the lower portion offrame member 284 in abuttable relationship against the contact surfaceof transition member 304. Accordingly, upon assembly, the frame contactperiphery of frame member 284 is aligned with the transition memberfirst contact surface in conjunction with a coupling which is carriedout with the stud connectors. Two manifold blocks 312 and 314 are seento be located and fixed within frame connector cavity 292. As discussedin connection with FIG. 8, these blocks are configured with manifoldopenings that extend through them thus permitting the insertion of theelongated rod portion 316 of a lifting eye represented generally at 318.Note that the rod extends into threaded engagement with a block form offoot represented at 320. At the upper region 280 a horizontal framemember represented generally at 322 is illustrated as having its contactend 324 abuttably coupled to the corresponding contact surface 326 oftransition member 302. Connection is provided by a stud connector 328.As before, in the course of assembly, the horizontal frame contactperiphery is aligned with the contact surface 326 and secured in thatorientation by the engagement of locking spacer collar 329 (seenpreviously as 166 in FIG. 5-6) with stud connector 328. Note thathorizontal frame member 322 is configured with transition edges 330 and332 which surmount matrix component 334.

The figure reveals that a top panel 336 is affixed over the top of theassemblage. In this regard it extends over the back surface 338 oftransition member 302. Note that a polymeric seal 340 has been locatedbetween the transition edge 330 and the inward side of top panel 336.

Now looking to the lower portion 282 of the assemblage, a lowerhorizontal frame member is represented generally at 342. As before,frame member 342 is assembled within the system by aligning its contactend 344 with the corresponding contact surface 346 of transition member304. A rigid connection is established through the utilization of studconnector 348, which connection can be further secured in a givenorientation by the engagement of locking spacer collar 349. As before,the horizontal frame member 342 is shown with transition edges 350 and352 which surmount polymeric matrix component 354.

In another embodiment of the invention, to facilitate temperatureregulation of the enclosure, environmentally conditioned fluids can beintroduced into the frame cavity as at 292 in FIG. 9, utilizing theframe cavity as a duct for conducting the conditioned fluids.Conditioned fluids could be directed from the frame cavity to aparticular location within an assembled enclosure inserting or removingscrews or plugs from different screw holes in the frame members. Inanother embodiment, access to the frame cavity is provided by use ofconnector screw 370. Referring to FIG. 10, a manifold screw isrepresented generally at 370. Screw 370 is formed with an internallydisposed port or channel 372 which may be internally threaded to receivea nipple. The screw is formed with a flat head 374 which is integrallyformed with an externally threaded stem 376. Hoses or other means todirect fluid flow are inserted into port 372 and extended to a locationaccessible to the frame to direct the flow of environmentallyconditioned fluid. The environmentally conditioned fluid could bevariously air, inert gases, or liquids such as water, and could be usedto heat, cool or pressurize particular components. It is envisioned bythe invention that both wiring and conditioned fluids could be presentin the same frame cavity.

Referring to FIG. 11, a section of the cap component 224 described inconnection with FIG. 8 is revealed incorporating the earlier-describedcap matrix member 260 and frame cap reinforcing member 256. The sectionof two frame carrying connectors 248 is shown. A feature of the instantarrangement resides in the arrangement wherein these frame carryingconnectors as at 248 lock the frame reinforcing member 256 to matrixmember 260. The remaining sides of each frame member can be similarlyconfigured. Male connectors can be formed on other components of theinvention, including frame member channels components, transitionmembers and accessory members, described below, using this method. Malecarrying connector 248 of FIG. 11 is formed of polymeric body matrix 260that passes through a perforation in cap reinforcing member 256. Whenmale carrying connector 248 possesses a larger diameter than theperforation, polymeric matrix material 260 will be affixed to capreinforcing member 256. Referring to FIG. 8, male carrying connectors248 are regularly spaced along the length of frame member cap component224. In one embodiment of the invention, sufficient male connectorsprotrude through cap reinforcing member 256 to retain polymeric matrix256 in contact with cap reinforcing member 256. In another embodiment ofthe invention, exposed surfaces of frame member cap component 224 andframe member channel component 192 are covered with regularly spacedmale connectors. In yet another embodiment of the invention, malecarrying connectors protrude from only a portion of the exposedsurfaces. Referring to FIG. 2 and FIG. 3, male carrying connectors 88can protrude from other system components, including transition members,vertical frame members, horizontal frame members and leg frame members.

An advantage of having the frame carrying connectors composed in part ofa frame reinforcing member is the increased strength of carryingconnectors, and resistance to wear typically found in materials utilizedin the frame reinforcing member compared to the polymeric matrixcomponent. Other portions of frame members and accessory members can besimilarly configured.

Male connectors 68 can be formed with a variety of other configurations.Referring to FIG. 12, another cap section is represented generally at378. The architecture represented by this section is one wherein theframe reinforcing member or frame cap reinforcing member 380 isconfigured having frame carrying connectors represented as male nodes382. In the male connector configuration of FIG. 12, the surface of themale connector is formed in part by the surface of the reinforcingelement. Such a reinforcing element could be cast, molded or pressed,and mated with body matrix. Note that the upper surface of each of thesemale nodes is configured with a vent hole 384. These vent holes 384facilitate the fabrication process wherein the polymeric matrixcomponent 386 is mated with the reinforcing member 380. If thereinforcing member 380 of FIG. 12 were used as an insert in a injectionmold, and polymeric body matrix was injected into the mold, it may benecessary to provide vent hole 384 in order to limit void formationbetween the body matrix component and the reinforcing member and assuresecure contact between body matrix member and reinforcing member. Thevent hole 384 also provides additional bearing surface to retain bodymatrix in contact with the reinforcing element. Vent hole 384 can incertain applications serve as a hole for insertion of a stud, rivet orself tapping screw. Depending on the properties of the materials formingbody matrix and reinforcing members, the male carrying connector FIG. 12is expected to exhibit greater shear resistance than the male connectorin FIG. 11.

The male connector can be formed of a number of shapes, with a preferredembodiment being a cylindrical shape. A cylindrical male carryingconnector as shown in FIG. 11 could have a diameter to height ratio ofapproximately 4 to 1, 2 to 1, 1 to 1, or 1 to 2, with a preferredembodiment having a diameter to height ratio of approximately 2 to 1.The proportions of the male carrying connector can be varied toaccommodate different applications, with important factors indetermining the proportions including the shear strength of materialforming the male carrying connector, the leverage a male carryingconnector is expected to experience, and whether the male carryingconnector is required primarily as a means for joining the body matrixmember to the reinforcing member or whether the male carrying connectoris needed as a means for aligning or attaching accessory members.

Looking to FIG. 13, another frame member cap section is representedgenerally at 388. Cap section 388 resembles FIG. 11 in that itincorporates frame cap reinforcing member 390, a polymeric matrixcomponent 392 and frame carrying connectors of a male variety shown at394. One variation on the cylindrical shape of a male connectorenvisioned is a male connector with a cap or lip that can function toincrease retention of mounted components. For this embodiment of theinvention, however, the top portions of the connectors 394 areconfigured with an integrally formed disc 396. Disc 396 may be employedfor specialized connector configurations wherein a slidably effectedengagement is contemplated. Other portions of frame members andaccessory members can be similarly configured, or configured to slidablyaccept carrying connectors such as connector 394.

Referring to FIG. 14, another frame member cap section is revealed ingeneral at 398. Section 398 exhibits a frame cap reinforcing member 400which is similar to that described in FIG. 12. This member 400 is matedwith polymeric matrix component 402. Frame carrying connectors 404 areconfigured in similar fashion as FIG. 12, each incorporating a vent hole406. For the instant embodiment, however, carrying connector discs 408are attached through the vent holes 406 by machine screws as at 410which extend into the matrix polymeric material. Thusly, the advantagesof carrying connectors 382 illustrated in FIG. 12 are combined with theadvantages of the carrying connector 394 of FIG. 13. A lipped maleconnector such as connectors 396 and 404 can also be formed by attachinga connector cap such as connector disc 408 to a male connector as 404shown in FIG. 14 using glue, welding or other means.

Referring to FIG. 15, a top view of an enclosure represented generallyat 420 is revealed. The view of enclosure 420 is shown with the removalof a top panel as described at 336 in FIG. 9. The view in FIG. 15 showstwo manners in which the enclosure can be used to house components. Suchinstallations are dependent on the components to be mounted and theflexibility of the frame systems allows wide variation in mountingsystems and equipment installation. Enclosure 420 is configured with twoadjacent and interconnected bays represented generally at 422 and 424.In this regard, bay 422 is configured with four upstanding verticalframe members 426-429. Seen in the figure is the inverted bottom surface432-435 of upper transition members. Connecting these inverted uppertransition members 432-435 are horizontal frame members. In this regard,horizontal frame member 438 is connected between vertical frame members429 and 426. Transition edges shown in the figure are represented at440-442. A horizontal frame member 444 is shown coupled between verticalcomponents 426 and 427. As before, the frame member 444 is illustratedwith transition edges 446-448. Finally, a horizontal frame member 450extends between the vertical supports 429 and 428 and is illustratedwith three transition edges 452-454. Frame member 450 is shown withthree transition edges, 452-454. Vertical components 426 and 427 areattached to respective corner completing accessories 456 and 458. Theseaccessories have a cross-section of triangular shape with a base surfacecorresponding with the back surface width of an associated transitionmember. The length of these accessories as at 456 and 458 whetherprovided as combinations of components or as a singular member willrepresent a combination of the upper frame back surfaces and lower frameback surfaces of the associated transition members as well as thevertical frame member extending between them. With the arrangementshown, a front transition plane is defined at 460; a rear transitionplane is defined at 462 and a side transition plane is defined at 464.To support electrical equipment within bay 422 a vertically orientedequipment support accessory having a triangular cross section as shownat 466 and 468 are attached to the vertical components of the framemember supports 428 and 427. Note the presence of an electrical chassis470 within the bay 422. Chassis 470 is attached to these accessories 466and 468 by a bracket 472. Slide rails as known in the art can besubstituted for brackets 472 to enable installation, maintenance andremoval of chassis 470. Note that a door 474 is attached to theaccessory 458 by a hinge 476. As described in connection with FIG. 1,door 474 carries a continuous seal as represented at 478 which engagesthe transition edges within forward transition plane 460.

Bay 422 is attached to bay 424. Looking to bay 424 it is seen to beformed of four vertical columnar supports 480-483. In this regard, theinverted back surfaces 486-489 of upper transition members are revealedat the four corners of the bay. Extending between vertical frame member483 and vertical frame member 480 is an upper horizontal frame member492. Three of the transition edges of this member 492 are revealed at493-495. Note that transition edge 493 falls within the transition plane462.

Extending between vertical supports 480 and 481 is an upper horizontalframe member 498. Three transition edges 499-501 are represented in thefigure. Note that transition edge 499 falls within a central transitionplane 504. The figure also reveals that transition edge 452 ofhorizontal member 450 is essentially coplanar with that transitionplane. An upper horizontal frame member 506 is seen to extend betweenvertical supports 483 and 482. Member 506 also is illustrated with threetransition edges 507-509. Note that transition edge 507 falls within aside transition plane 512. Finally, an upper horizontal frame member 514interconnects vertical support 481 and 482. Further, three transitionedges 515-517 are revealed and it may be noted that transition edge 515is coplanar with transition plane 460.

Corner completing accessories 520 and 522 having a triangularcross-section are mounted to the orderly disposed surfaces of verticalsupports 482 and 483. These corner accessories provide a flat cornersurface. In this regard, the flat surface of accessory 522 is shownsupporting a hinge 524 of a door 526. Similar to bay 422, bay 424incorporates vertical accessory supports 528 and 530 which are attachedto one face of the vertical corner supports 480 and 483. Connected tothose support accessories 528 and 530 is a vertical support panel 532upon which is mounted electrical equipment represented at block 534.

The supporting frames of base 422 and 424 are juxtaposed to define thosetwo bays such that the rearward vertically disposed corner region ofsupport 429 abuts a corresponding rearward vertically disposed cornerregion of support 480. This develops two rearward angularly outwardlyoriented frame faces 536 and 538 which define a rearward outwardlyextended space of triangular cross-section.

In the same manner the forward vertically disposed corner region ofvertical support 428 abuts the forward vertically disposed corner regionof support 481. This provides two forward angularly outwardly orientedframe faces 540 and 542 defining another rearward outwardly extendingspace of triangular cross-section. Coupled between the frame withinthese spaces are inter-bay completing accessories having a cross-sectionof triangular shape corresponding with the spaces of triangular crosssection. Thus, an inter-bay completing accessory 544 connects verticalcomponents 480 and 429 and a corresponding inter-bay completingaccessory 546 connects the vertical supports 428 and 481.

A back panel 548 is seen to extend across the combined bays 422 and 424and is sealed to the frame members as represented at seal 550 at bay422. In similar fashion, seal 552 engages back panel 548 at bay 424. Insimilar fashion, a seal 554 engages a side panel 556 at the right sideof the enclosure 420 as represented in the figure. A left side panel 558is sealed to the bay 424 at seal 560. Next, a seal 562 located attransition plane 504 sealably supports the inter-bay connection. Note,additionally, door 526 contacts a continuous seal as represented at 564which engages the transition edges adjacent the forward transition plane460.

As described above, the surfaces of the frame members of the inventioncan be constructed to expose regularly spaced male carrying connectors,as at 88, on the faces of the frame members. The spacing of maleconnectors facilitates attachment and alignment of accessory componentmembers female connector sockets.

The accessory components exhibiting a triangular cross-section are ofquite simple structure. In this regard, looking at FIG. 16, such anaccessory of triangular configuration is revealed in general at 570.Accessory 570 shown having a rectangular base surface 572 extendinginwardly from the surface 572 is an array of regularly spaced femalecarrying connectors, certain of which are identified at 574.

Looking to FIG. 17, a cross section of the accessory 570 connected to avertical frame member represented generally at 576 is shown. Member 576is shown having a reinforcing component 578 is described in general inconnection with FIG. 8. Internally within that component is matrixcomponent 580 which is integrally formed with frame male carryingconnectors 582 which are seen to engage corresponding accessory femalecarrying connectors 574. The union thus provided may be reinforced witha suitable adhesive. Note that accessory component 570 as shown is notconstructed of hybrid materials. Accessory components (and as notedpreviously, frame member components) can be alternatively constructed ofhybrid materials in those situations where the particular requirementsof the installation warrant hybrid construction.

Looking to FIG. 18, a cross section of another accessory of triangularcross-section is represented in general at 584 is shown. Accessory 584is combined with a vertical frame member represented generally at 586.As in FIG. 17 the member 586 is configured with an outwardly disposedreinforcing component which surmounts a polymeric matrix component 590.Connection with this arrangement is reinforced by a sequence of screws,two of which are shown at 592 which extend from the seats of acorresponding sequence of screw retaining cavities as represented at 594into engagement with the polymeric matrix component 590.

Another form of coupling involves the utilization of a cam lockingapproach formed in conjunction with the male frame carrying connectors.Looking to FIG. 19, an alternative accessory component is representedgenerally at 600. Accessory 600 as before, exhibits a triangularcross-section and is a rectangular based surface 602. As in the case ofFIG. 16, the accessory 600 is configured with female connectors 604depending inwardly from the base surface 602. Male carrying connectors604 assist in aligning and supporting accessory component 600 wheninstalled on a frame member. Additionally extending inwardly from thebase surface 602 are locking cavities as at 606 and 608. Within each ofthese locking cavities there is provided an externally rotatable camcomponent shown respectively at 610 and 612. The cavities 606 and 608engage four of the male frame carrying connectors generally at thecorners thereof. Thus, by rotating the cam a locking feature isrealized. Looking additionally to FIG. 20, a cross section of accessory600 reappears in conjunction with a vertical frame member representedgenerally at 614. As before, the frame member 614 incorporates areinforcing component 616 which surmounts a polymeric matrix component618. Note that a cavity 620 extends from the apex of the cross-sectionof accessory 600 which carries a cam actuator head 622 which may berotated with a suitable tool such as a screwdriver. Looking to FIG. 21,this locking arrangement is represented in general at 624. In thefigure, a cam as at 610 reappears within cavity 606. Four frame membercarrying connectors of a male structuring are represented in phantom at626. It may be observed, that by rotating cam 610, a locking action willbe realized.

The frame structures of the invention additionally are configured suchthat horizontal accessory bars may be employed with them. Referring toFIG. 22, a cross section of such a horizontal accessory bar isrepresented generally at 628. Accessory bar 628 is seen to be coupledbetween two vertical frame members represented generally at 630 and 632.As before, frame member 630 is configured with an outwardly disposedreinforcing component 634 which surmounts a polymeric matrix component636. Note that one angularly disposed face 638 of the member 630functions to support the accessory bar 628. In similar fashion, framemember 632 is configured with an outwardly disposed reinforcingcomponent 640 which surmounts a polymeric matrix component 642. Theangularly oriented face 644 of member 632 also is seen to support theopposite end of accessory bar 628. In this regard, the angularlyoriented oppositely disposed faces 646 and 648 of accessory bar 628 areconfigured with elongated female connectors, for instance, connectors650 extend inwardly from accessory bar face 646, while inwardlydepending female connectors 652 extend inwardly from face 648. Becauseinsertion within conventional female connectors would be difficult forthe arrangement of FIG. 22, the female connectors are elongated. Thisfeature is illustrated in FIG. 23. Referring to FIG. 23, three bar face646 reappears in conjunction with elongated female connectors 650.

The accessory components utilized with the instant system and themselvesbeing modularized. For example, one can be stacked atop anotherutilizing the connector approach illustrated. Looking to FIG. 24, a topview of such a connector is represented in general at 660. Accessory 660is configured with a top surface 662 from which extend male connectorscertain of which are represented at 664. Looking additionally to FIG.25, a side view of the accessory 660 is presented. Two of these topconnectors are represented at 664. Note additionally that oppositelydisposed male connectors are provided at a surface 666 from which extendmale connectors, two of which are seen at 668. End surface 670 also isconfigured with inwardly depending female connectors certain of whichare represented at 672. These connectors 672 also may be seen in phantomin connection with FIG. 24. Returning to FIG. 25, each side 674 and 676of accessory 660 is configured with inwardly depending femaleconnectors. In this regard, female connectors certain of which areidentified at 678 extend inwardly from side 674, while correspondingfemale connectors certain of which are identified at 680 extend inwardlyfrom side 676. Turning again to FIG. 24, it may be observed that maleconnectors, certain of which are identified at 682 extend outwardly fromend of surface 684.

Referring to FIGS. 26 and 27, an accessory bar similar to that describedin conjunction with FIG. 22 is represented in general at 690. Theoutwardly disposed surface 692 of accessory 690 is seen to supportoutwardly depending male connectors certain of which are identified at694. The opposite surface of accessory 690 at 696 also is seen tosupport an array of male connectors certain of which are identified at698. FIG. 26 shows one side surface 700 from which orderly depends anarray of male connectors certain of which are identified at 702.Correspondingly, as represented in FIG. 27, the face opposite face 700as at 704 supports outwardly depending male connectors certain of whichare revealed at 706. Alternatively, surface 740 can be configured withinwardly depending female carrying connectors, as at 672 of FIG. 24 toallow modular stacking and interlocking of multiple accessory components690. As shown in FIG. 26 and 27, accessory 690 further is configuredhaving an annularly disposed connecting surface 708 which incorporates alocking connector represented generally at 710 which includes aninwardly depending locking cavity 712 internally of which a rotatablelocking cam 714 is disposed. As seen in FIG. 26, access to the cam 714is seen in FIG. 26 to be through an access channel represented generallyat 716.

Since certain changes may be made to the above-described apparatus andmethod without departing from the scope of the invention hereininvolved, it is intended that all matter contained in the abovedescription or shown in the accompanying drawings shall be interpretedas illustrative and not in a limiting sense. All terms not definedherein are considered to be defined according to Webster's New TwentiethCentury Dictionary Unabridged Second edition.

1. The method of making a frame comprising the steps of: providing twoor more linear frame members of given length extending along a frameaxis between oppositely disposed frame contact ends exhibiting framecontact peripheries and a frame cross-section exhibiting at least twosymmetrically opposite linear edges; providing one or more transitionmembers each with a first component extending along a first axis alength less than said given length to a first contact surface exhibitinga first edge profile corresponding with said frame cross section, saidedge profile being oriented about said first axis to position twoopposite edges within a first plane extending along said first axis,said transition member having an integrally formed second componentextending along a second axis normal to said first axis a length lessthan said given length to a second contact surface exhibiting a secondedge profile corresponding with said frame cross-section and orientedabout said second axis to position two opposite edges within a secondplane normally disposed with respect to said first plane, and anintegrally formed third component extending along a third axis normal tosaid first and second axes a length less than said given length to athird contact surface exhibiting a third edge profile corresponding withsaid frame cross-section, said third edge profile being oriented aboutsaid third axis to position two opposite edges within said second plane.aligning a frame contact periphery of a frame member with said firstedge profile and abuttably coupling linear frame member to a transitionmember first contact surface; aligning a frame contact periphery withsaid second edge profile and abuttably coupling a linear frame member toa transition member second contact surface; aligning a frame contactperiphery with said third edge profile and abuttably coupling a linearframe member to a transition member third contact surface; andreiterating said aligning and coupling steps.
 2. The method of claim 1further comprising the step: providing three or more stud connectorseach having oppositely disposed first and second connector portions;said step providing two or more linear frame members provides said framemembers with frame connector cavities extending axially mutuallyinwardly from said frame contact ends; said step providing said one ormore transition members provides each transition member as beingconfigured having a transition connector cavity extending axiallyinwardly from said first, second and third contact surfaces; and saidsteps of aligning and coupling a transition member with frame membersare carried out by inserting a said stud connector first connectorportion within a frame connector cavity and inserting said studconnector second connector portion within a said transition connectorcavity.
 3. The method of claim 1 in which: said transition member isprovided further comprising a fourth component extending along saidfirst axis opposite said first component a length less than said givenlength to a fourth contact surface exhibiting a fourth edge profilecorresponding with said frame cross-section, said fourth edge profilebeing oriented about said first axis in alignment with said firstcomponent edge profile to locate said edge profile to position twoopposite edges within said first plane.
 4. The method of claim 3 furthercomprising the step: aligning a frame contact periphery of a fourthframe member with said translation member fourth component edge profilewhile abuttably coupling said fourth contact surface with a framecontact end.
 5. The method of claim 4 further comprising the step:providing one or more stud connectors each having oppositely disposedfirst and second connector portions; said step providing two or morelinear frame members provides said frame members with frame connectorcavities extending axially mutually inwardly from said frame contactends; said step providing one or more transition members provides eachtransition member as being configured having a transition connectorcavity extending axially inwardly from said first, second, third andfourth contact surfaces; and said steps of aligning and coupling atransition member with frame members are carried out by inserting a saidstud connector first connector portion within a frame connector cavityand inserting said stud connector second connector portion within a saidtransition connector cavity.
 6. The method of claim 1 in which: one ormore of said frame members is configured having a generally axiallydisposed frame open channel extending between said oppositely disposedframe contact ends; and one or more said transition members isconfigured having inwardly depending and commonly joined transition openchannels generally disposed about said first, second and third axes,said transition open channels being generally aligned with a said frameopen channel when the contact periphery thereof is aligned with atransition member component edge profile.
 7. The method of claim 1 inwhich: said one or more transition members are provided with aconfiguration wherein the outwardly disposed one of two edges of saidfirst component extends inwardly from within a first contact surfacetransition plane; the outwardly disposed one of two edges of said secondcomponent extends inwardly from within said transition plane; and saidfirst component outwardly disposed edge and said second componentoutwardly disposed edge being joined in said transition plane as acontinuous first transition edge;
 8. The method of claim 7 in which:said continuous transition edge exhibits a medial curvature.
 9. Themethod of claim 1 in which: said one or more transition members areprovided with a configuration wherein the outermost one of said firstcomponent two opposite edges located in said first plane extendsinwardly from said first contact surface within a transition plane; theoutermost one of said third component two opposite edges extendsinwardly from said third contact surface within said transition plane;said first component outermost edge and said third component outermostedge being joined in said transition plane as a continuous transitionedge.
 10. The method of claim 9 in which: said transition edge exhibitsa medial curvature.
 11. The method of claim 3 in which: said one or moretransition members are provided with a configuration wherein theoutermost one of said fourth component two opposite edges located insaid first plane extends inwardly from said fourth contact surfacewithin a transition plane; the outermost one of said two opposite edgesof said second component extends inwardly from said second contactsurface within said transition plane; and the outermost one said fourthcomponent edge and the outermost one said second component edge beingjoined in said transition plane as a continuous transition edge.
 12. Themethod of claim 11 in which: said transition edge exhibits a medialcurvature.
 13. The method of claim 3 in which: said one or moretransition members are provided with a configuration wherein theoutermost one of said two opposite edges located in said first planeextend inwardly from said fourth contact surface within a transitionplane; the outermost one of said two opposite edges of said thirdcomponent extends inwardly from said third contact surface within saidtransition plane; and said fourth component outermost edge and saidthird component outermost edge being joined in said transition plane asa continuous fourth transition edge.
 14. The method of claim 1 in which:a said transition member is provided being configured having anoutwardly disposed flat back surface of back surface length and widthdisposed normally to an axis passing through said first axis andbisecting a corner angle defined by said second and third axes andhaving one or more frame carrying connectors integrally formed with saidback surface; said step providing two or more frame members provides oneor more of said frame members with one or more flat surfaces having anarray of integrally formed said frame carrying connectors; said step ofaligning and coupling a frame member locates said frame member to be avertically disposed frame member with said flat surface aligned withsaid transition member back surface. said steps of aligning and couplingframe members locates them to define a frame corner; further comprisingthe steps: providing a corner completing accessory having a cornerlength corresponding with said given length plus said back surfacelength, a cross-section of triangular shape to provide a base surfacewith a base width corresponding with said back surface width andextending said corner length and having two oppositely disposed sidesextending to define a corner edge, said base surface being configuredwith accessory connectors corresponding and connectable with said backsurface and flat surface connectors; and coupling said corner completingaccessory at said base surface to a frame member flat surface to definea corner by interconnecting said frame carrying connectors with saidaccessory connectors.
 15. The method of claim 14 in which: said step forproviding two or more frame members provides one or more of said framemembers with one or more flat surfaces having an array of said framecarrying connectors which are outwardly depending male connectors; andsaid step providing a corner completing accessory provides saidaccessory connectors as inwardly depending female connectors.
 16. Themethod of claim 1 in which: said steps for aligning and coupling saidtwo or more frame members with said one or more transition members arecarried out to derive a frame structure with two adjacent bays whereintwo vertically oriented frame members are located in mutual adjacencywherein a linear edge of one frame member abuts a linear edge of theadjacent frame member, said frame cross section of each is generallysquare to provide two angularly oriented frame faces extending outwardlyfrom said abutting linear edges to define an outwardly extending spaceof triangular cross section, said frame faces each having an array ofintegrally formed frame carrying connectors; further comprising thesteps: providing an inter-bay completing accessory having across-section of triangular shape corresponding with said space oftriangular cross-section, having an outwardly disposed base face andmutually inwardly angularly extending side faces each being configuredwith an array of integrally formed accessory connectors correspondingwith said array of frame carrying connecters; and coupling saidinter-bay completing accessory at said side faces to said two angularlyoriented frame faces by interconnecting said frame carrying connectorswith said accessory connectors.
 17. The method of claim 16 in which:said step for providing two or more frame members provides saidangularly oriented frame faces with said integrally formed framecarrying connectors as outwardly depending male connectors; and saidstep providing an inter-bay completing accessory provides said accessoryconnectors as inwardly depending female connectors.
 18. A frame system,comprising: a plurality of linear frame members of given lengthsextending along a frame axis between oppositely disposed contact ends,said contact ends exhibiting frame contact peripheries, the framemembers exhibiting a frame cross-section having at least twosymmetrically opposite linear edges extending to two symmetricallyopposite corners of said frame contact peripheries; a plurality oftransition members each with a first component extending along a firstaxis a length less than said given length to a first contact surfaceexhibiting an edge profile corresponding with a frame contact periphery,said edge profile being oriented about said first axis to position twoopposite edges within a first plane extending along said first axis,said transition member having a second component extending along asecond axis normal to said first axis a length less than said givenlength to a second contact surface exhibiting an edge profilecorresponding with said frame cross-section and oriented about saidsecond axis to position two opposite edges within a second planenormally disposed with respect to said first plane, said transitionmember having a third component extending along a third axis normal tosaid first and second axes a length less than said given length to athird contact surface exhibiting an edge profile corresponding with saidframe cross-section, said edge profile being oriented about said thirdaxis to position two opposite edges within said second plane, and saidtransition member having a fourth component extending along said firstaxis opposite said first component a length less than said given lengthto a fourth contact surface exhibiting an edge profile correspondingwith said frame cross-section, said edge profile being oriented aboutsaid first axis in alignment with said first component edge profile tolocate said edge profile to position two opposite edges within saidfirst plane; a plurality of said transition members being designatedlower frame transition members, and a plurality being designated upperframe transition members; a plurality of said frame members beingdesignated vertical frame members, and a plurality being designatedhorizontal frame members; the oppositely disposed contact ends of aplurality of said vertical frame members being coupled between the firstcontact surface of a plurality of said lower frame transition membersand the fourth contact surface of a plurality of said upper frametransition members; the oppositely disposed contact ends of a pluralityof said horizontal frame members being coupled between the secondcontact surfaces and the third contact surfaces of a plurality of lowerframe transition members to define a lower frame portion; and theoppositely disposed contact ends of a plurality of said horizontal framemembers being coupled between the second contact surfaces and the thirdcontact surfaces of a plurality of upper frame transition members todefine the upper frame portion of a frame having a plurality ofvertically disposed corner regions extending between oppositely disposedupper frame transition members and lower frame transition members. 19.The frame system of claim 18 in which: said linear frame members areconfigured with frame connector cavities extending axially mutuallyinwardly from said frame contact ends; said transition members areconfigured having a transition connector cavity extending axiallyinwardly from said first, second, third and fourth contact surfaces;said frame system further comprising a plurality of stud connectors eachhaving a first connector portion configured for engagement within aframe connector cavity and an oppositely disposed second connectorportion engageable within a transition connector cavity to effectcoupling between frame members and transition members.
 20. The framesystem of claim 18 in which: said linear frame members are configuredhaving a generally axially disposed frame open channel extending betweensaid oppositely disposed frame contact ends; and said transition membersare configured having inwardly depending and commonly joined transitionopen channels generally disposed about said first, second, and thirdaxes.
 21. The frame system of claim 18 in which: the outermost one ofsaid two opposite edges of said first component of each said transitionmember extends inwardly from said first contact surface within atransition plane; the outermost one of said two opposite edges of saidsecond component of each said transition member extends inwardly fromsaid second contact surface within said transition plane; and said firstcomponent outermost edge and said second component outermost edge beingjoined in said transition plane as a continuous transition edge.
 22. Theframe system of claim 21 in which: said continuous transition edgeexhibits a medial curvature.
 23. The frame system of claim 18 in which:the outermost one of said two opposite edges of said first component ofeach said transition member extends inwardly from said first contactsurface within a transition plane; the outermost one of said twoopposite edges of said third component of each said transition memberextends inwardly from said third contact surface within said transitionplane; and said first component outermost edge and said third componentoutermost edge being joined in said transition plane as a continuoustransition edge.
 24. The frame system of claim 23 in which: saidcontinuous transition edge exhibits a medial curvature.
 25. The framesystem of claim 18 in which: the outermost one of said two oppositeedges of said fourth component of each said transition member extendsinwardly from said fourth contact surface within a transition plane; theoutermost one of said two opposite edges of said second component ofeach said transition member extends inwardly from said second contactsurface within said transition plane; and said fourth componentoutermost edge and said second component outermost edge being joined insaid transition plane as a continuous transition edge.
 26. The framesystem of claim 25 in which: said continuous transition edge exhibits amedial curvature.
 27. The frame system of claim 18 in which: theoutermost one of said two opposite edges of said fourth component ofeach said transition member extends inwardly from said fourth contactsurface within a transition plane; the outermost one of said twoopposite edges of said third component of each said transition memberextends inwardly from said third contact surface within said transitionplane; and said fourth component outermost edge and said third componentoutermost edge being joined in said transition plane as a continuoustransition edge.
 28. The frame system of claim 27 in which: saidcontinuous transition edge exhibits a medial curvature.
 29. The framesystem of claim 18 in which: each said transition member is configuredhaving an outwardly disposed flat back surface of back surface lengthand width disposed normally to an axis passing through said first axisand bisecting a corner angle defined by said second and third axes, saidback surface facing outwardly at said corner region and having a framecarrying connector assemblage formed with said back surface; each saidvertical frame member coupled between a said upper frame transitionmember and a said lower frame transition member having a flat surfacealigned with the adjacent back surfaces and including a frame carryingconnector assemblage; said frame system further comprising; and a cornercompleting accessory having a cross-section of triangular shape with abase surface corresponding with said back surface width and a basesurface length substantially coextensive with said upper frame backsurface, said lower frame back surfaces and said vertical frame memberand having two oppositely disposed sides extending to define a corneredge, said base being configured with an accessory connector assemblageconnected with said frame carrying connector assemblages.
 30. The framesystem of claim 29 in which: said frame member frame cross-sectiondefines four flat orthogonally disposed surfaces with one or more saidflat surfaces having a said frame connecter assemblage comprising anarray of frame connectors; each said transition member back surfaceframe carrying connector assemblage comprises an array of said frameconnectors; and said corner completing accessory base accessoryconnector assemblage comprises an array of accessory connectors.
 31. Theframe system of claim 30 in which: said frame connectors are outwardlydepending male connectors; and said accessory connectors are inwardlydepending female connectors.
 32. The frame system of claim 18 in which:said frame cross-section is substantially square; two said frames arejuxtaposed to define two bays wherein a forward vertically disposedcorner region of one frame abuts the forward vertically disposed cornerregion of the other frame to provide two forward angularly outwardlyoriented frame faces defining a forward outwardly extending space oftriangular cross-section, said frame faces of said combination eachhaving a frame carrying connector assemblage; further comprising aforward inter-bay completing accessory having a cross-section oftriangular shape corresponding with said space of triangularcross-section, having an outwardly disposed face and mutually inwardlyangularly extending side faces each being configured with an accessoryconnector assemblage; and said forward inter-bay completing accessorybeing coupled with said angularly outwardly oriented frame faces byinterconnecting said frame carrying connector assemblages with saidaccessory connector assemblage.
 33. The frame system of claim 32 inwhich: each said frame connector assemblage comprises an array ofoutwardly depending male connectors; and each said accessory connectorassemblage comprises an array of outwardly depending female connectors.34. The frame system of claim 32 in which: said two frames arejuxtaposed to define two bays wherein a rearward vertically disposedcorner region of one frame abuts the rearward vertically disposed cornerregion of the other frame to provide two rearward angularly outwardlyoriented frame faces defining a rearward outwardly extending space oftriangular cross-section, said frame faces of said combination eachhaving a frame carrying connector assemblage; further comprising arearward inter-bay completing accessory having a cross-section oftriangular shape corresponding with said space of triangular crosssection, having an outwardly disposed face and mutually inwardlyangularly extending side faces, each being configured with an accessoryconnector assemblage; and said rearward inter-bay completing assemblybeing coupled with said angularly outwardly oriented frame faces byinterconnecting said frame carrying connector assemblages with saidaccessory connector assemblages.
 35. The frame system of claim 34 inwhich: each said frame connector assemblage comprises an array ofoutwardly depending male connectors; and each said accessory connectorassemblage comprises an array of outwardly depending female connectors.36. The frame system of claim 19 in which: one or more of said framemembers comprise: a generally U-shaped channel component having anoutwardly open cap receiving side and configured with a generallyU-shaped reinforcing member having three outwardly disposed frame facesand a reinforcing member cavity extending between said oppositelydisposed contact ends; a polymeric channel matrix member located withinsaid reinforcing member cavity configured to define a portion of saidframe connector cavities extending inwardly from said frame contact endsand further configured to define a matrix bottom wall and side wallsextending outwardly to spaced apart cap engagement ledges adjacent saidoutwardly open cap receiving side; a cap component configured forpositioning over said channel component open cap receiving side andhaving a generally flat cap reinforcing member with an outwardlydisposed frame face and an inwardly attached polymeric cap matrix memberhaving oppositely and axially disposed spaced apart engagement surfacesengaging said spaced apart cap engagement ledges, said cap matrixmember, with said channel matrix member, defining said frame connectorcavities; and a connector assembly coupling said cap component with saidchannel component.